Hi. I'm getting all the bits I need to replace the front shocks on my wife's Polo; the shocks (!), balljoint splitter, spring compressor, breaker bar, notched socket for removing the top nut etc., and reading through the Haynes manual last night, it mentioned a VW Special Tool "40-201B" would be needed to remove the shock cartridge from the strut.

Is this really needed ? Can I make do ? This is getting expensive on the tool front, and I haven't even started the job yet !!

Hi. I'm getting all the bits I need to replace the front shocks on my wife's Polo; the shocks (!), balljoint splitter, spring compressor, breaker bar, notched socket for removing the top nut etc., and reading through the Haynes manual last night, it mentioned a VW Special Tool "40-201B" would be needed to remove the shock cartridge from the strut.

Is this really needed ? Can I make do ? This is getting expensive on the tool front, and I haven't even started the job yet !!

Are we talking A Mk3 polo here?

I usually use a vice.. I WOULD not like to use any other makeshift tool as these will really be corroded on. Pliers, mole grips etc never ever cut it.

Are we talking A Mk3 polo here?

I usually use a vice.. I WOULD not like to use any other makeshift tool as these will really be corroded on. Pliers, mole grips etc never ever cut it.

Nah, it's 'facelift' Mk2 - 1993, AAU. Where is this nut then ? I've seen a pic of the tool, and it looks like nothing more than a very long socket. What does the nut it's removing actually do ?

Hi. I'm getting all the bits I need to replace the front shocks on my wife's Polo; the shocks (!), balljoint splitter, spring compressor, breaker bar, notched socket for removing the top nut etc., and reading through the Haynes manual last night, it mentioned a VW Special Tool "40-201B" would be needed to remove the shock cartridge from the strut.

Is this really needed ? Can I make do ? This is getting expensive on the tool front, and I haven't even started the job yet !!

by the time you,ve bought all them tools etc and the shocks you,d probably be as well to just have a pair fitted at a local kwikfit or something and not have to have the hassle

It's a bit late for that I'm afraid ! I've already bought everything apart from this special tool. Besides, I've got to change the O/S/F wheel bearing, so I may as well do it all in one go.

Are we talking A Mk3 polo here?

I usually use a vice.. I WOULD not like to use any other makeshift tool as these will really be corroded on. Pliers, mole grips etc never ever cut it.

Nah, it's 'facelift' Mk2 - 1993, AAU. Where is this nut then ? I've seen a pic of the tool, and it looks like nothing more than a very long socket. What does the nut it's removing actually do ?

Yeah, its what we call a Mk3.. Mk2F.. 86c, All the same to us!

Its hard to explain. Where the shock cartridge is placed into the strut, imagine a long cylinder with one open end to place it in.. That end has a thread and is sealed with a nut.. this nut is a more of a cap.. Like a dome with a female nut shape pressed inside. It's pretty big; like 30cm or something. Meaning you have nothing to grab, no flat sides apart from the very thin hex recess inside. Obviously the shock strut is protruding through the middle of it so a normal 30mm-ish hex key wont work..

So the only way to remove it is with a special tool or something with lots of grabbing force.. i.e A vice. I've done this about 10 times and I've never been able to do it any other way.

Oh bugger I've been googling since my last post, and it looks like a right b**tard to do. Particularly as I don't have a vice.

Haynes manuals used to be great... full of tips and DIY tool suggestions. Now it's "Use VW Tool 40-201B to remove the cartridge retaining cap". No mention of you needing a 60ft scaffold tube and a herd of bull elephants.

Oh dear... I don't know what to do now.

I don't want to start it if I can't finish it properly. I don't have a vice and I can't even find that tool to buy on the internet ! The front shocks leaking were an advisory on the last MOT. I might be tempted to just do the wheel bearing and get shot of the car. It would save me a lot of hassle.

Anyone know what the likes of KwikFit might charge to replace the shocks ?

Oh bugger I've been googling since my last post, and it looks like a right b**tard to do. Particularly as I don't have a vice.

Haynes manuals used to be great... full of tips and DIY tool suggestions. Now it's "Use VW Tool 40-201B to remove the cartridge retaining cap". No mention of you needing a 60ft scaffold tube and a herd of bull elephants.

Oh dear... I don't know what to do now.

I don't want to start it if I can't finish it properly. I don't have a vice and I can't even find that tool to buy on the internet ! The front shocks leaking were an advisory on the last MOT. I might be tempted to just do the wheel bearing and get shot of the car. It would save me a lot of hassle.

Anyone know what the likes of KwikFit might charge to replace the shocks ?

Thing is.. the replace the bearings you need the strut out.. Then you need a press for the bearings. Can you not take the strut with the new insert and bearing to a garage and slip em £20 or something to press the bearing in and out and remove/replace that big nut?

I just used a massive set of stilsons that i had knocking about :) just wd40 them a bit and youll be fine :)

I've done a load of them for friends and its an easy job (I'm lowering but same thing) I've also found that instead of undoing the steering arm bolt (its a bitch as it spins) remove the other end from the steering rack as this takes literally seconds! this also gives you some leverage when undoing the troublesome bolt that you absolutely dont need a special tool for. Everyone should have a set of stilsons as they are good for so many things

I just used a massive set of stilsons that i had knocking about :) just wd40 them a bit and youll be fine :)

I've done a load of them for friends and its an easy job (I'm lowering but same thing) I've also found that instead of undoing the steering arm bolt (its a bitch as it spins) remove the other end from the steering rack as this takes literally seconds! this also gives you some leverage when undoing the troublesome bolt that you absolutely dont need a special tool for. Everyone should have a set of stilsons as they are good for so many things

Yeah that'd work! I don't own a set though.

Yeah, I was planning on taking the hub to an engineering place anyway to get them to press out the old bearing and press in the new, but.... I have concerns that they might give it to the spotty apprentice / teaboy who would just botch it to get the cartridge out and not torque the cap up correctly. Having seen the standard of some garage work, I'd be surprised if the majority of those did it properly either !

The only way to be sure that it's been done properly is to do it myself, and it bugs me that I can't, because I don't have a hydraulic press and the special VW strut cap tool.

Why does it need to be torqued up so ridiculously high ?

How have you managed on the ones you've done ? Did you just get the caps off in a vice / stilsons, and when tightening them back up, stop when your face went purple ? :-D

I would second that.

Remove the strut yourself and get a good local garage to do the work.

It would be more of an interest to a garage though if you asked them to supply the parts as well.

Regards.

Yeah, I was planning on taking the hub to an engineering place anyway to get them to press out the old bearing and press in the new, but.... I have concerns that they might give it to the spotty apprentice / teaboy who would just botch it to get the cartridge out and not torque the cap up correctly. Having seen the standard of some garage work, I'd be surprised if the majority of those did it properly either !

The only way to be sure that it's been done properly is to do it myself, and it bugs me that I can't, because I don't have a hydraulic press and the special VW strut cap tool.

Why does it need to be torqued up so ridiculously high ?

How have you managed on the ones you've done ? Did you just get the caps off in a vice / stilsons, and when tightening them back up, stop when your face went purple ? :-D

Pretty much..

Surly a vice is only like £20 from machine mart.. Might be worth investing in one?

How have you managed on the ones you've done ? Did you just get the caps off in a vice / stilsons, and when tightening them back up, stop when your face went purple ? :-D

Pretty much yea, my stilsons are the best part of 2ft long so theres plenty of torque there! I've done 5 sets now and I've never really struggled to get one off!

Where abouts are you?

I'm in Swansea, Wales. Bit of a trek up to Stoke I could invest in a vice I suppose.... and a set of stilsons. Jesus, this thing is going to cost me about £200 with all the bits & bobs. The car can't be worth much more than that !

What do you do with the cap ? Does it tend to get mangled coming off ? Do you refit the old ones ?

I'm in Swansea, Wales. Bit of a trek up to Stoke I could invest in a vice I suppose.... and a set of stilsons. Jesus, this thing is going to cost me about £200 with all the bits & bobs. The car can't be worth much more than that !

What do you do with the cap ? Does it tend to get mangled coming off ? Do you refit the old ones ?

Refit the old ones.. they are hard as ****

You've commited now, so an extra £20 won't hurt!

Ah well, would have been handy if you were close! i have not used a vice any of the times, but i think you'll only need one of them, but both are handy tools to have anyway! :)

And yea, i always just refit!

Edited 29 March, 201115 yr by salty

Machine Mart or Screwfix in llansamlet. :)

You use the old cap, shouldnt get mangled as its pretty thick, best way to get the castle nut off is to use the weight of the car to hold the spring down then good soak with plusgas/wd40 and some molegrips or stilsons, remove nut and strut.

Or remove the strut but use spring compressors.

As you in Swansea mate give http://httuning.10.forumer.com/index.php a look, someone close might be able to lend a hand for coffee/tea and biscuits

Edited 29 March, 201115 yr by Cymro

Thanks guys. Much appreciated. I'll get a stilsons and a vice I think...

Bloody car !

Luckily for me, I just take my company car to the main dealers and can say "fix it my man.... and don't skimp on the cost"

Unfortunately, the same doesn't apply to the wife's little polo.

No worries dude, its all good when we can help each other out :) If you do need any help, i have loads of pictures from when i lowered robbodred's coupe a couple of weeks ago!

...In fact, check out his build thread as i think some are already up Robbo is lazy and makes me fix his car

Edited 29 March, 201115 yr by salty

Thanks again for the help everyone. I was just telling the Mrs what a great place this forum is I might take you up on the photos... once I get round to starting the job.

Thanks again !

Edited 29 March, 201115 yr by aneng

No worries, pm me if you do need any help as i wont find this topic again! And dont go saying stuff like that, it'll go to our heads

Stilsons and a vice will do the job. Can't believe someone suggested taking it to kwikfit! I don't even think they do stuff like that and even if they did I'd not go anywhere near there.

What's the consensus on where's best to get parts from ? GSF are slightly more expensive for the 2 shocks and 1 wheel bearing, Eurocarparts are about a tenner cheaper, but I've been reading some negative stuff about them - i.e. the 'Anschler' shocks are made in India or China, and I didn't have a good experience with them last time round to be honest.

GSF don't actually specify a brand for any of the parts, so I'm none the wiser.

Where do you guys get your parts ?

I'm always gsf man myself really :)